Ceiling construction

ABSTRACT

An air circulating or distributing ceiling construction incorporating suspended fiber mat filters which, while effective for the entrapment of airborne dust particles and the like, is also capable of effectively passing light, sound and liquid from concealed lights, speakers, and a ceiling mounted fire extinguishing system, the filters also having some sound absorbing qualities as well. Additional sound absorption is provided by locating sound absorbing material behind the filters thus avoiding an impairment of the capabilities of the sound absorbing means by airborne dust and the like. The use of filters in lieu of the conventional concealment methods of glass, plastic, etc., will allow the use of a smaller fan motor, thus a reduction in noise and electricity.

United States Patent Akins 1 1 CEILING CONSTRUCTION [76] Inventor: MarkM. Akins, 7203 Rollingwood Dr., Chevy Chase, Md. 20015 221 Filed: Sept.11, 1973 21 Appl. No.; 396,153

[52] US. Cl. 52/27; 52/144; 52/220;

55/DIG. 16; 98/40 D [51] Int. Cl. E04F l7/04 [58] Field of Search 52/27,28, 145, 144, 168,

52/220, 222,221, 173; 98/40 D, 40 DL; 55/524, DIG. l6

[56] References Cited UNITED STATES PATENTS 2,218,453 10/1940 Mickle 1.55/DlG. 16

2,251,663 8/1941 Darbo 1 4 1 4 98/40 D 2,683,408 7/1954 Brown et a1. 198/40 D 2,384,512 4/1959 Wakefield 98/40 D X 3,084,492 4/1963 Dorsak eta]. 55/DIG. 16

3,376,805 4/1968 Deddo et al. 98/40 D X 3,482,505 12/1969 Sawyer ct a].98/40 D [4 1 Sept. 9, 1975 3,559,560 2/1971 Trahan 98/40 D PrimaryExaminer-Price C. Faw, Jr. Attorney, Agent, or FirmDennis0n, Dennison,

Townshend & Meserole [57] ABSTRACT An air circulating or distributingceiling construction incorporating suspended fiber mat filters which,while effective for the entrapment of airborne dust particles and thelike, is also capable of effectively passing light, sound and liquidfrom concealed lights, speakers, and a ceiling mounted fireextinguishing system, the filters also having some sound absorbingqualities as well Additional sound absorption is provided by locatingsound absorbing material behind the filters thus avoid ing an impairmentof the capabilities of the sound ab sorbing means by airborne dust andthe like. The use of filters in lieu of the conventional concealmentmethods of glass, plastic, etc., will allow the use of a smaller fanmotor, thus a reduction in noise and electricity.

9 Claims, 4 Drawing Figures i fgg 1 i 33 III/A tram "av-WE] W ages/ 1-All? FLOW CEILING CONSTRUCTION The present invention relates to new anduseful improvements in ceiling construction and is particularlyconcerned with construction wherein uniquely devised filters areutilized so as to conceal, protect and maintain at peak operatingefficiency various desired ceiling mounted systems includingillumination systems, loud speaker systems, fire extinguishing systemsand sound absorbing systems.

Basically, a ceiling constructed in accordance with the invention willincorporate an air circulating or distributing duct system normallyincorporating both supply and return ducts. in order to reduce air flowgenerated noises, the ducts will have appropriate acoustical or soundabsorbing material associated therewith. In addition, the low frictionloss of the filters in comparison to the conventional concealmentmethods of glass, plastic, etc. will allow the use of a smaller fan andfan motor, and thus will reduce the noise level and electric power.Further, the ceiling will incorporate illuminating means, soundabsorbing material to entrap noise generated from the underlying room orarea, and, depending on the particular installation, a public addresssystem of multiple speakers and a liquid distributing fire extinguishingsystem. Underlying all of these components as a concealing andprotective means therefor is a system of fiber mats or filters which actso as to entrap airborne dust particles in the return air before theyreach the air circulation system and any dust particles in the supplyair (clean air) which may have not been entrapped by the ceiling returnair ceiling filter or the central filter system (when needed foradditional air purity such as a central electronic filter) so as tomaintain the concealed systems, components and materials at peakoperating efficiency. By the same token, the filters are so constructedas to, in a substantially unimpeded manner, allow the transmission ofair, light, sound and, in the event of a fire, liquid. The filtersthemselves will be constructed of continuous fibers of glass,polyethylene, or polyester bonded by an appropriate thermosetting resinproviding a generally selfsustaining or supported mat.

Other objects and advantages of the invention will become apparent fromthe following description in conjunction with the accompanying drawingswherein:

FIG. I is a cross sectional view through one type of ceilingincorporating the features of the invention;

FIG. 2 is a similar view through a second form of ceiling;

FIG. 3 is a cross sectional detail through one type of filterconstructed in accordance with the instant invention; and

FIG. 4 is a cross sectional detail through a second form of filter.

Referring now more specifically to the drawings, it is initially pointedout that while the ceiling construction system of the invention can beadapted to basically any type of ceiling, it is shown herein forsimplicity incorporated into a coffered ceiling or one provided withapparatus accommodating bays. In this regard, FIG. I illus trates aceiling construction wherein laterally spaced parallel support beamssupport an overlying deck l2 and define a series of bays I4. With thistype of construction, the air circulating or distributing duet system,generally designated by reference numeral 16, is appropriately suspendedwithin the bays l4.

In the arrangement of FIG. 2, the deck 18 is integrally formed withdepending beam-like ribs 20 arranged in either laterally spacedelongated runs or in a grid pattern defining, in either case, theceiling bays or coffers 14 for the accommodation of various ceilingmounted systems. In the construction of FIG. 2, it will be noted thatthe air circulating or distributing network of ducts 16 actually has thedeck formed thereabout.

The air circulating duct system 16, regardless of the overall ceilingconstruction, while it can consist of solely supply ducts or solelyreturn ducts, will normally incorporate both supply and return ductsarranged so as to provide an effective circulation of air through theunderlying room or area.

Each bay 14 incorporating a portion of the duct system 16, whether thisbe every bay or selected bays, may be provided with sound absorbingacoustical material 22. This material 22 preferably lines the bay and isso arranged as to provide an effective sound deadening means whereby asubstantial amount of sound is absorbed from the noise generated fromthe room or area below. Sound absorbing material 33 may also be placedon the air circulating duct system to absorb the noise generated by airpassing through the duct system.

The ceiling construction of the invention will also incorporateappropriate illumination means 24 which may take any form, for example,fluorescent tubing as illustrated. Also, if deemed desirable for aparticular installation, sound projection means 26, such as aconventional public address systems, can be provided, as well as anoverhead fire extinguishing water sprinkling system 28. ln eachinstance, assuming a bay or eoffer ceiling, the various components willbe positioned within the bays or coffers provided, or immediatelyadjacent thereto.

All of the above components are concealed and protected by an underlyingsystem of filters 30 which define the under surface of the ceilingconstruction. These filters, removable for access to the concealedcomponents as well as periodic replacement as required, can be in theform of elongated strips or sheets. However, such filters will normallyconsist of individual rectangular mats releasably mounted in appropriaterectangular frames 32 of any suitable type which are in turn eitherpivotally or slip mounted in the manner of conventional suspendedceiling panels and as suggested in FIGS. 1 and 2. The mats arepreferably coated with an oily substance to aid in filtration.

The filters specifically act so as to entrap and extract airborne dustparticles and the like from the circulating air, and are effective ineither direction of air flow. As such, the various concealed lights,sound reproduction systems, fire extinguishing systems, and the like aremaintained in a clean and protected environment resulting in reducedfriction in the air flow. ln conjunction therewith, and particularlysignificant, is the fact that the acoustical sound absorbing material22, which in almost all instances is ofa porous nature for the mosteffective sound absorbing capabilities, is protected against airbornedirt and maintained clean so as to retain its maximum noise absorbingcapabilities. In other words, conventional sound absorbing materialwill, over a period of time, have the various sound absorbing pores,openings, or the like gradually filled and closed off by the absorptionof foreign material therein. This in turn greatly reduces the ability ofthe sound absorbing material to properly function. The provision ofseparate filters, of a disposable and easily replaceable nature,eliminates the normally expected deterioration of the sound absorbingcapabilities of the acoustical material.

The filters 30 of the invention, in addition to filtering the air flowso as to maintain the acoustical material and other components of theconstruction in a clean state, provide in effect a continuous lowerlayer on the ceiling. As such, the filters are specifically constructedso as to, while effectively filtering the air, not interfere with theoperation of the remaining components. In other words, the filters 30are capable of passing or transmitting light from the light sources 24,sound from the sound sources 26, and, should a fire emergency arise,water from the sprinkler systems 28. Additionally, the filters are sodesigned as to have some sound absorbing qualities with the remainingnoise generated below passing through the filter to be entrapped by thesound absorbing acoustical material 22.

In order to function in this manner, the filter mats are formed ofcontinuous filament fibers of glass, polyethylene, or polyester bondedtogether with an appropriate thermosetting resin which polymerizes at atemperature below the degradation point of the particular fi bers whichform the matrix being bonded.

In the form of filter 30 illustrated in FIG. 3, the filter consistsbasically of two layers, 40 micron diameter fibers loosely woven orfelted on the air entering side of the filter and 25 micron diameterfibers closely woven or felted on the air exiting side of the filter. Inanother form, illustrated in FIG. 4, a constant density fiberarrangement can be provided wherein fibers of approximately 30 micronsin diameter are utilized throughout the extent of the filter. Aspreviously indicated, the fibers are bonded by an appropriatethermosetting resin resulting in a self-sustaining mat which, in anyreasonable size, can be supported by a peripheral frame. Shouldadditional support be required, thin cross braces can be provided on thesupporting frame. In any case, the filters are to be easily removed forreplacement purposes at regular intervals. [t is contemplated that inorder to function in the proposed manner, a one inch thick filter shouldhave an air flow resistance equal to approximately 7/100 inch on aconventional water gauge. A 2 inch filter should have approximately a1/10 inch water gauge resistance measurement.

Other features can be incorporated into the ceiling construction ascontemplated. For example, the filters can be colored as desired forpleasing aesthetic effects. The filtration material may be made withpores for yet additional sound absorption. In addition, release meanscan be incorporated therein so as to dispense, as an example, perfumesand the like. Incidentally, it should be appreciated that the provisionof the filters which can be periodically replaced enables the use of anair flow system of less overall capacity and noise emission than thatwhich would be required were no replaceable filtering means provided.

The foregoing is considered as illustrative only of the principles ofthe invention. Further, since numerous modifications and changes willreadily occur to those skilled in the art, it is not desired to limitthe invention to the exact construction and operation shown anddescribed, and accordingly, all suitable modifications and equivalentsmay be resorted to, falling within the scope of the invention.

I claim:

1. An air circulating ceiling construction including a system inlet andexhaust ducts, sound absorbing means provided adjacent said ducts forthe muffling of air flow induced noises and for absorbing noises fromthe room below, and filter panels mounted below said ducts and soundabsorbing means and in the path of air flow to and from the room, saidfilter panels defining the exposed surface of the ceiling and consistingof a fibrous air pervious medium defined by micro-size fibers looselyfelted in a substantially homogeneous manner and defining air passageswhich are the sole passages through said panels, said fibers beingbonded into a self-sustaining mat with said air passages formed by andbetween the fibers and the fibers effecting entrapment of airborne dustparticles and the like, said fibrous medium having sound transmittingcapabilities whereby the sound absorbing means is maintained clean andits sound absorbing capability unimpaired.

2. The construction of claim 1 including a light source mounted abovesaid filter panels, said filter panels being of a light passing natureand serving to conceal said light source, and to prevent dustaccumulation on light bulbs and resulting light reduction.

3. The construction of claim 2 including a sound source mounted abovesaid filter panels, said filter panels being of a sound passing nature.

4. The construction of claim 3 including a water dispensing fireextinguishing system mounted above said filter panels, said filterpanels being of a water passing nature.

5. An air circulating ceiling construction including a system inlet andexhaust ducts, sound absorbing means provided adjacent said ducts forthe muffling of air flow induced noises and for absorbing noises fromthe room below, filter panels mounted below said ducts and soundabsorbing means and in the path of air flow to and from the room, saidfilter panels defining the exposed surface of the ceiling and effectingentrapment of airborne dust particles and the like whereby the soundabsorbing means is maintained clean and its sound absorbing capabilityunimpaired, a light source mounted above said filter panels, said filterpanels being of a light passing nature and serving to conceal said lightsource, and to prevent dust accumulation on light bulbs and resultinglight reduction, a sound source mounted above said filter panels, saidfilter panels being of a sound passing nature, and a water dispensingfire extinguishing system mounted above said filter panels, said filterpanels being of a water passing nature, said filter panels being formedof bonded continuous fibers approximately 25 to microns in diameter.

6. The construction of claim 4 wherein each filter panel has an airentering side and an air leaving side, said filter panels being formedof two layers of bonded continuous fibers, said bonded fibers on theentering side of each filter panel being approximately 40 microns indiameter, said bonded fibers on the leaving side of said filter panelbeing approximately 25 microns in diameter.

7. An air circulating ceiling construction including a system inlet andexhaust ducts, sound absorbing means provided adjacent said ducts forthe muffiing of air flow induced noises and for absorbing noises fromthe room below, and filter panels mounted below said ducts and soundabsorbing means and in the path of air flow to and from the room, saidfilter panels defining the exposed surface of the ceiling and effectingentrapment of airborne dust particles and the like whereby the soundabsorbing means is maintained clean and its sound absorbing capabilityunimpaired, said filter panels being formed of bonded continuous fibersapproximately to microns in diameter.

8. An air circulating ceiling construction including a system inlet andexhaust ducts, sound absorbing means rovided adjacent said ducts for themuffling of air flow induced noises and for absorbing noises from theroom below, and filter panels mounted below said ducts and soundabsorbing means and in the path of air flow to and from the room, saidfilter panels defining the exposed surface of the ceiling and effectingentrapment of airborne dust particles and the like whereby the soundabsorbing means is maintained clean and its sound absorbing capabilityunimpaired, each filter panel having an air entering side and an airleaving side, said filter panels being formed of two layers of bondedcontinuous fibers, said bonded fibers on the entering side of eachfilter panel being approximately 40 microns in diameter, said bondedfibers on the leaving side of said filter panel being approximately 25microns in diameter.

9. The construction of claim 1 wherein said filter panels are formed ofbonded continuous fibers no greater than approximately 40 microns indiameter.

1. An air circulating ceiling construction including a system inlet andexhaust ducts, sound absorbing means provided adjacent said ducts forthe muffling of air flow induced noises and for absorbing noises fromthe room below, and filter panels mounted below said ducts and soundabsorbing means and in the path of air flow to and from the room, saidfilter panels defining the exposed surface of the ceiling and consistingof a fibrous air pervious medium defined by micro-size fibers looselyfelted in a substantially homogeneous manner and defining air passageswhich are the sole passages through said panels, said fibers beingbonded into a self-sustaining mat with said air passages formed by andbetween the fibers and the fibers effecting entrapment of airborne dustparticles and the like, said fibrous medium having sound transmittingcapabilities whereby the sound absorbing means is maintained clean andits sound absorbing capability unimpaired.
 2. The construction of claim1 including a light source mounted above said filter panels, said filterpanels being of a light passing nature and serving to conceal said lightsource, and to prevent dust accumulation on light bulbs and resultinglight reduction.
 3. The construction of claim 2 including a sound sourcemounted above said filter panels, said filter panels being of a soundpassing nature.
 4. The construction of claim 3 including a waterdispensing fire extinguishing system mounted above said filter panels,said filter panels being of a water passing nature.
 5. An aircirculating ceiling construction including a system inlet and exhaustducts, sound absorbing means provided adjacent said ducts for themuffling of air flow induced noises and for absorbing noises from theroom below, filter panels mounted below said ducts and sound absorbingmeans and in the path of air flow to and from the room, said filterpanels defining the exposed surface of the ceiling and effectingentrapment of airborne dust particles and the like whereby the soundabsorbing means is maintained clean and its sound absorbing capabilityunimpaired, a light source mounted above said filter panels, said filterpanels being of a light passing nature and serving to conceal said lightsource, and to prevent dust accumulation on light bulbs and resultinglight reduction, a sound source mounted above said filter panels, saidfilter panels being of a sound passing nature, and a water dispensingfire extinguishing system mounted above said filter panels, said filterpanels being of a water passing nature, said filter panels being formedof bonded continuous fibers approximately 25 to 40 microns in diameter.6. The construction of claim 4 wherein each filter panel has an airentering side and an air leaving side, said filter panels being formedof two layers of bonded continuous fibers, said bonded fibers on theentering side of each filter panel being approximately 40 microns indiameter, said bonded fibers on the leaving side of said filter panelbeing approximately 25 microns in diameter.
 7. An air circulatingceiling construction including a system inlet and exhaust ducts, soundabsorbing means provided adjacent said ducts for the muffling of airflow induced noises and for absorbing noises from the room below, andfilter panels mounted below said ducts and sound absorbing means and inthe path of air flow to and from the room, said filter panels definingthe exposed surface of the ceiling and effecting entrapment of airbornedust particles and the like whereby the sound absorbing means ismaintained clean and its sound absorbing capability unimpaired, saidfilter panels being formed of bonded continuous fibers approximately 25to 40 microns in diameter.
 8. An air circulating ceiling constructionincluding a system inlet and exhaust ducts, sound absorbing meansprovided adjacent said ducts for the muffling of air flow induced noisesand for absorbing noises from the room Below, and filter panels mountedbelow said ducts and sound absorbing means and in the path of air flowto and from the room, said filter panels defining the exposed surface ofthe ceiling and effecting entrapment of airborne dust particles and thelike whereby the sound absorbing means is maintained clean and its soundabsorbing capability unimpaired, each filter panel having an airentering side and an air leaving side, said filter panels being formedof two layers of bonded continuous fibers, said bonded fibers on theentering side of each filter panel being approximately 40 microns indiameter, said bonded fibers on the leaving side of said filter panelbeing approximately 25 microns in diameter.
 9. The construction of claim1 wherein said filter panels are formed of bonded continuous fibers nogreater than approximately 40 microns in diameter.